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INSTALLATION MANUAL CHAMPION®PLUS SINGLE PACKAGED GAS/ELECTRIC AIR COOLED AIR CONDITIONERS 1-1/2 THROUGH 5 NOMINAL TON CONTENTS GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DNH: 018 024 030 036 042 048 060 RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . 15 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . 15 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 23 TYPICAL WIRING DIAGRAM NOTES . . . . . . . . . . . . . 31 See the following page for a complete Table of Contents. NOTES, CAUTIONS AND WARNINGS The installer should pay particular attention to the words: NOTE, CAUTION, and WARNING. Notes are intended to clarify or make the installation easier. Cautions are given to prevent equipment damage. Warnings are given to alert installer that personal injury and/or equipment damage may result if installation procedure is not handled properly. CAUTION: READ ALL SAFETY GUIDES BEFORE YOU BEGIN TO INSTALL YOUR UNIT. ISO 9001 Certified Quality Management System SAVE THIS MANUAL 66324-YIM-B-1004 66324-YIM-B-1004 TABLE OF CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 APPROVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 RIGGING OR HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . 5 CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DUCT WORK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 ROOF CURB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SERVICE ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 POWER AND CONTROL WIRING . . . . . . . . . . . . . . . . . . 6 COMPRESSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 COMBUSTION DISCHARGE . . . . . . . . . . . . . . . . . . . . . . 9 GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 GAS CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FLUE VENT HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SEQUENCE OF OPERATION. . . . . . . . . . . . . . . . . . . . 15 HEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 CIRCULATING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 PRE-START CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . 15 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 15 TO TURN OFF GAS TO UNIT. . . . . . . . . . . . . . . . . . . . . 15 POST-START CHECK LIST (GAS). . . . . . . . . . . . . . . . . 16 MANIFOLD GAS PRESSURE ADJUSTMENT . . . . . . . . 16 BURNER INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . 16 HOT SURFACE PILOT INSTRUCTIONS . . . . . . . . . . . . 17 ADJUSTMENT OF TEMPERATURE RISE . . . . . . . . . . . 17 DIRECT DRIVE BLOWER. . . . . . . . . . . . . . . . . . . . . . . 17 CHECKING GAS INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 17 NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SECURE OWNER'S APPROVAL . . . . . . . . . . . . . . . . . . 18 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 NORMAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 18 FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 MOTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 OUTDOOR COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 BURNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 TO CLEAN BURNERS . . . . . . . . . . . . . . . . . . . . . . . . . 19 COMBUSTION AIR DISCHARGE . . . . . . . . . . . . . . . . . . 19 CLEANING FLUE PASSAGES AND HEATING ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CHECKING SUPPLY AIR CFM. . . . . . . . . . . . . . . . . . . . 19 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . 23 TYPICAL WIRING DIAGRAM NOTES . . . . . . . . . . . . . 31 2 LIST OF FIGURES Fig. # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Pg. # PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . 4 UNIT CENTER OF GRAVITY . . . . . . . . . . . . . . . . . 5 FIELD WIRING DIAGRAM CONTROL WIRING . . . 7 POWER WIRING FIELD DIAGRAM . . . . . . . . . . . . 7 EXTERNAL SUPPLY CONNECTION EXTERNAL SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 FLUE VENT OUTLET AIR HOOD . . . . . . . . . . . . . 11 UNIT DIMENSIONS - FRONT . . . . . . . . . . . . . . . . 13 UNIT DIMENSIONS - FRONT & BOTTOM . . . . . . 14 UNIT DIMENSIONS - BACK & BOTTOM . . . . . . . 14 GAS VALVE - FRONT . . . . . . . . . . . . . . . . . . . . . . 16 GAS VALVE - REAR . . . . . . . . . . . . . . . . . . . . . . . 16 PROPER FLAME ADJUSTMENT . . . . . . . . . . . . . 17 IGNITOR AND FLAME SENSOR ASSEMBLY . . . 17 D1NH COIL DELTA P VS. AIRFLOW . . . . . . . . . . 20 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 23 TYPICAL WIRING DIAGRAM D1NH 018, 024, 030, 036, 048 (208/230-1-60 POWER SUPPLY). . . . . . 24 TYPICAL WIRING DIAGRAM D1NH 030, 036, 042, 048 (208/230-3-60 POWER SUPPLY). . . . . . . . . . 25 TYPICAL WIRING DIAGRAM D1NH 030, 036, 042, 048 (460-3-60 POWER SUPPLY) . . . . . . . . . . . . . 26 TYPICAL WIRING DIAGRAM D1NH 036, 042, 048, 060 (575-3-60 POWER SUPPLY) . . . . . . . . . . . . . 27 TYPICAL WIRING DIAGRAM D1NH 060 (208-230-1-60 POWER SUPPLY) . . . . . . . . . . . . . 28 TYPICAL WIRING DIAGRAM D1NH 060 (208-230-3-60 POWER SUPPLY) . . . . . . . . . 29 TYPICAL WIRING DIAGRAM D1NH 060 (460-3-60 POWER SUPPLY). . . . . . . . . . . . . . . . . 30 WIRING DIAGRAM DETAIL B (460 & 575-3-60 POWER SUPPLY) . . . . . . . . . . . 31 TYPICAL WIRING DIAGRAM LEGEND . . . . . . . . 31 LIST OF TABLES Tbl. # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Pg. # UNIT APPLICATION DATA. . . . . . . . . . . . . . . . . . . . . . 4 UNIT WEIGHTS AND CENTER OF GRAVITY . . . . . . . 5 NATURAL GAS APPLICATION DATA . . . . . . . . . . . . . 8 PROPANE (LP) GAS APPLICATION DATA . . . . . . . . . 9 NATURAL GAS PIPE SIZING CHART . . . . . . . . . . . . 10 PROPANE (LP) GAS PIPE SIZING CHART . . . . . . . . 10 PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . 12 UNIT DIMENSIONS FRONT . . . . . . . . . . . . . . . . . . . . 13 UNIT MINIMUM CLEARANCES . . . . . . . . . . . . . . . . . 13 GASE RATE - CUBIC FEET PER HOUR . . . . . . . . . . 18 SUPERHEAT CHARGING TABLE FOR D1NH018 . . 20 SUPERHEAT CHARGING TABLE FOR D1NH024 . . 21 SUPERHEAT CHARGING TABLE FOR D1NH030 . . 21 SUPERHEAT CHARGING TABLE FOR D1NH036 . . 21 SUPERHEAT CHARGING TABLE FOR D1NH042 . . 22 SUPERHEAT CHARGING TABLE FOR D1NH048 . . 22 SUPERHEAT CHARGING TABLE FOR D1NH060 . . 22 Unitary Products Group 66324-YIM-B-1004 GENERAL APPROVALS YORK Model D1NH units are cooling/heating air conditioners designed for outdoor installation. Only gas piping, electric power and duct connections are required at the point of installation. Design certified by CGA and AGA listed as follows: 1. For use as a forced air furnace with cooling unit. 2. For outdoor installation only. The gas-fired heaters have hot surface to pilot ignition. The tubular heat exchangers are aluminized steel. 3. For installation directly on combustible flooring or, in U.S., on wood flooring or Class A; B; C roof covering material. This appliance is not to be used for temporary heating of buildings or structures under construction. 4. For installation on combustible material. 5. For use with natural gas and/or propane (LP) gas. Not suitable for use with conventional venting systems. Installer should pay particular attention to the words; NOTE, CAUTION, and WARNING. NOTES are intended to clarify or make the installation easier. CAUTIONS are given to prevent equipment damage. WARNINGS are given to alert the installer that personal injury and/or equipment damage may result if installation procedure is not handled properly. INSPECTION As soon as a unit is received, it should be inspected for possible damage during transit. If damage is evident, the extent of the damage should be noted on the carrier's freight bill. A separate request for inspection by the carrier's agent should be made in writing. Refer to Form 50.15-NM for additional information. RENEWAL PARTS For key Replacement Parts, refer to Renewal Parts Form: • • • • This product must be installed in strict compliance with the enclosed installation instructions and any applicable local, state, and national codes including, but not limited to, building, electrical and mechanical codes. Improper installation may create a condition where the operation of the product could cause personal injury or property damage. 530.46-RP1.1Y 530.46-RP1.2Y 530.46-RP2.1Y 530.46-RP3.1Y Unitary Products Group 3 66324-YIM-B-1004 D 1 N H 0 2 4 N 0 3 6 0 6 V O L T A G E C O D E P R O D U C T C A T E G O R Y 0 6 = 2 5 = 4 5 D = S in g le P a c k a g e A ir C o n d itio n e r P R O D U C T G E N E R A T IO N 2 0 2 0 6 = 8 = 8 /2 8 /2 4 6 0 5 7 5 3 0 3 0 -3 -3 -1 -3 -6 -6 0 -6 0 -6 0 0 1 = 1 s t G e n e r a tio n P R O D U C T ID E N T IF IE R N H = 1 2 S E E R N O M IN A L C O O L IN G C A P A C IT Y (M B H ) G a s H e a t/E le c tr ic 0 1 0 2 0 3 0 3 0 4 0 4 0 6 8 = 4 = 0 = 6 = 2 = 8 = 0 = 1 8 2 4 3 0 3 6 4 2 4 8 6 0 ,0 ,0 ,0 ,0 ,0 ,0 ,0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 B T B T B T B T B T B T B T U H U H U H U H U H U H U H F A C T O R Y IN S T A L L E D G A S H E A T N = N a tu r a l G a s H e a t In s ta lle d N O M IN A L G A S H E A T IN G O U T P U T C A P A C IT Y 0 3 6 = 0 5 6 = 0 7 2 = 0 6 5 = 0 9 0 = 1 1 0 = 3 6 ,0 0 0 5 6 ,0 0 0 7 2 ,0 0 0 6 5 ,0 0 0 9 0 ,0 0 0 1 1 0 ,0 0 0 B T B T B T B T B T B T U H U H U H U H U H U H FIGURE 1 - PRODUCT NOMENCLATURE INSTALLATION LOCATION LIMITATIONS Use the following guidelines to select a suitable location for these units. These units must be installed in accordance with the following national and local safety codes. 1. Unit is designed for outdoor installation only. 1. National Electrical Code ANSI/NFPS No. 70 or Canadian Electrical Code Part 1, C22.1 (latest editions). 2. 2. National Fuel Gas Code Z223.1 or CAN/CGA B149.1 or.2 Installation Code. Condenser must have an unlimited supply of air. Where a choice of location is possible, position unit on either north or east side of building. 3. Local gas utility requirements. 4. Local plumbing and waste water codes and other applicable local codes. Excessive exposure of this furnace to contaminated combustion air may result in equipment damage or personal injury. Typical contaminants include: permanent wave solution, chlorinated wastes and cleaners, chlorine based swimming pool chemicals, water softening chemicals, carbon tetrachloride, halogen type refrigerants, cleaning solvents (e.g. perchloroethylene), printing inks, paint removers, varnishes, hydrochloric acid, cements and glues, antistatic fabric softeners for clothes dryers, masonry acid washing materials. Refer to Table 1 for unit application data and to Table 2 for gas heat application data. If components are to be added to a unit to meet local codes, they are to be installed at the dealer's and/or the customer's expense. Size of unit for proposed installation should be based on heat loss/heat gain calculations made in accordance with industry recognized procedures identified by the Air Conditioning Contractors of America. 3. For ground level installation, a level pad or slab should be used. The thickness and size of the pad or slab used should meet local codes and unit weight. Do not tie the slab to the building foundation. 4. For roof top installation, be sure the structure will support the weight of the unit plus any field installed components. Unit must be installed on a level roof curb or appropriate angle iron frame providing adequate support under the compressor/condenser section. 5. Maintain level tolerance of unit to 1/8" maximum. TABLE 1: UNIT APPLICATION DATA Voltage Variation 1 Min. / Max. 208/230V2 187 / 253 460V 414 / 504 575V 518 / 630 Wet Bulb Temperature (°F) of Air on Evaporator Coil, Min. / Max. Dry Bulb Temperature (°F) of Air on Condenser Coil, Min.3 / Max. 1. 2. 3. 4 57 / 72 45 / 120 Rated in accordance with ARI Standard 110, utilization range “A”. “T1” transformer primary tap must be moved from the 230 volt connection to the 208 volt connection for low voltage applications of 208 volt and below A low ambient accessory is available for operation down to 0 °F. Unitary Products Group 66324-YIM-B-1004 RIGGING OR HANDLING CLEARANCES Care must be exercised when moving the unit. Do not remove any packaging until the unit is near the place of installation. Rig unit with slings placed under the unit. Spreader bars of sufficient length should be used across the top of the unit. All units require certain clearances for proper operation and service. Refer to Figure 5 for the clearances required for combustion, construction, servicing and proper unit operation. Do not permit overhanging structures or shrubs to obstruct the condenser air discharge, combustion air inlet or vent outlet. Before lifting a unit, make sure that its weight is distributed equally on the cables so that it will lift evenly. Units may also be moved or lifted with a fork-lift. Slotted openings in the skid are provided for this purpose. Forks must pass completely through the base. Refer to Table 2 for unit weights and to Figure 2 for approximate center of gravity. TABLE 2: UNIT WEIGHTS AND CENTER OF GRAVITY These units are adaptable to downflow use as well as rear supply and return air duct openings. To convert to downflow, use the following steps: 1. Remove the duct covers found in the bottom return and supply air duct openings. There are four (4) screws securing each duct cover (save these screws to use later). 2. Install the duct covers, removed in step one, to the rear supply and return air duct openings. Secure with the four (4) screws used in step one. 3. Seal duct covers with silicone caulk. CORNER WEIGHTS (LOCATION, LBS.) SHIPPING WEIGHT (LBS.) OPERATING WEIGHT (LBS.) “A” “B” “C” “D” 018 365 360 91 88 89 92 024 365 360 91 88 89 92 030 395 390 98 95 96 99 036 400 395 100 96 98 101 042 470 465 131 129 101 103 048 475 470 133 130 102 104 060 485 480 136 133 105 107 UNIT SIZE DUCT WORK Duct work should be designed and sized according to the methods of the Air Conditioning Contractors of America (ACCA), as set forth in their Manual D. A closed return duct system shall be used. This shall not preclude use of economizers or ventilation air intake. Flexible joints may be used in the supply and return duct work to minimize the transmission of noise. "D" CENTER OF GRAVITY FRONT OF UNIT "C" "A" 49-1/8 FIGURE 2 - 25 "B" 25 UNIT CENTER OF GRAVITY Unitary Products Group When fastening duct work to the side duct flanges on the unit, insert the screws through the duct flanges only. Do not insert the screws through the casing. Outdoor ductwork must be insulated and waterproofed. 47-1/4 NOTE: Be sure to note supply and return openings. Refer to Figure 5 for information concerning rear and bottom supply and return air duct openings. 5 66324-YIM-B-1004 ROOF CURB On applications when a roof curb is used, the unit must be positioned on the curb so the front of the unit is tight against the curb. FILTERS Single phase units are shipped without a filter or filter racks and is the responsibility of the installer to secure a filter in the return air ductwork or install a Filter/Frame Kit (1FF0110). A filter rack and a high velocity filters are standard on three phase units. Filters must always be used and must be kept clean. When filters become dirt laden, insufficient air will be delivered by the blower, decreasing your units efficiency and increasing operating costs and wear-and-tear on the unit and controls. Filters should be checked monthly especially since this unit is used for both heating and cooling. CONDENSATE DRAIN A condensate trap is recommended to be installed in the condensate drain. The plumbing must conform to local codes. Use a sealing compound on male pipe threads. Install the condensate drain line (NPTF) to spill into an open drain. Refer to Figure 5 for location of these access panels and minimum clearances. THERMOSTAT The room thermostat should be located on an inside wall approximately 56" above the floor where it will not be subject to drafts, sun exposure or heat from electrical fixtures or appliances. Follow manufacturer's instructions enclosed with the thermostat for general installation procedure. Four color coded insulated wires (minimum #18 AWG) should be used to connect thermostat to unit. See Figure 2. POWER AND CONTROL WIRING Field wiring to the unit must conform to provisions of the current N.E.C. ANSI/NFPA No. 70 or C.E.C. and/or local ordinances. The unit must be electrically grounded in accordance with local codes or, in their absence, with the N.E.C./C.E.C. Voltage tolerances which must be maintained at the compressor terminals during starting and running conditions are indicated on the unit Rating Plate and Table 8. The wiring entering the cabinet must be provided with mechanical strain relief. A fused disconnect switch should be field provided for the unit. If any of the wire supplied with the unit must be replaced, replacement wire must be of the type shown on the wiring diagram. SERVICE ACCESS Access to all serviceable components is provided by the following removable panels: • • 6 Blower compartment Gas control/electrical service access Electrical line must be sized properly to carry the load. Each unit must be wired with a separate branch circuit fed directly from the meter panel and properly fused. Refer to Figure 2 for typical field wiring and to the appropriate unit wiring diagram for control circuit and power wiring information. Unitary Products Group 66324-YIM-B-1004 NOTE: HEAT ANTICIPATOR SHOULD BE SET AT 0.35 AMPS FOR ALL MODELS. THERMOSTAT UNIT TERMINAL STRIP ** = Minimum wire size of 18 AWG wire should be used for all field installed 24 volt wire. ** R R G G Y Y W W C C 24 VOLT TRANSFORMER PROGRAMMABLE THERMOSTAT ONLY FIGURE 3 - FIELD WIRING DIAGRAM CONTROL WIRING C O N T A C T O R C O N T A C T O R F IE L D -S U P P L IE D D IS C O N N E C T G R O U N D L U G FIGURE 4 - R E F E R T O E L E C T R IC A L D A T A T A B L E S T O S IZ E T H E D IS C O N N E C T S IN P H P O S U G L E A S E W E R P P L Y F IE L D -S U P P L IE D D IS C O N N E C T G R O U N D L U G R E F E R T O E L E C T R IC A L D A T A T A B L E S T O S IZ E T H E D IS C O N N E C T T H R P H A P O W S U P E E S E E R P L Y POWER WIRING FIELD DIAGRAM Unitary Products Group 7 66324-YIM-B-1004 COMPRESSORS Units are shipped with compressor mounting factory-adjusted for shipping. Loosen compressor mounting bolts a half turn before operating unit. TABLE 3: NATURAL GAS APPLICATION DATA AVAILABLE ON MODELS (MBH)1 TEMP. RISE °F AT FULL OUTPUT CAPACITY (MBH) GAS RATE2 FT.3/HR. NUMBER OF BURNERS INPUT3 MIN. MAX. 1-1/2, 2, 2-1/2 3 TON 45 36 42 2 25 55 2 & 2-1/2 TON 70 56 65 3 30 60 3 TON 70 56 65 3 25 55 3-1/2 TON, 4 & 5 TON 80 64 74 3 25 55 3 TON 90 72 84 4 30 60 3-1/2 TON 108 87 100 4 45 75 4 & 5 TON 108 87 43 4 30 60 4 & 5 TON 135 108 126 5 35 65 1. Heating capacity valid for elevations up to 2000 feet above sea level. For elevations above 2,000 feet, rated capacity should be reduced by 4% for each 1,000 feet above sea level. 2. Based on 1075 BTU/Ft.3. The air flow must be adjusted to obtain a temperature rise within the range shown. Continuous return air temperature should not be below 55°F. 3. 8 INPUT CAPACITY Unitary Products Group 66324-YIM-B-1004 TABLE 4: PROPANE1 (LP) GAS APPLICATION DATA TEMP. RISE ×F AT FULL AVAILABLE ON MODELS INPUT CAPACITY (MBH)2 GAS RATE3 OUTPUT CAPACITY (MBH) 3 FT. /HR. INPUT4 NUMBER OF BURNERS MIN. MAX. 1-1/2, 2, 2-1/2, 3 TON 45 36 18 2 25 55 2 & 2-1/2 TON 70 56 28 3 30 60 3 TON 70 56 28 3 25 55 3-1/2, 4 & 5 TON 80 64 32 3 25 55 3 TON 90 72 36 4 30 60 3-1/2 TON 108 87 43 4 45 75 4 & 5 TON 108 87 43 4 30 60 4 & 5 TON 135 108 54 5 35 65 1. 2. 3. 4. Propane applications are accomplished by field installation of a Propane Conversion Accessory, Model 1NP0805. Heating capacity valid for elevations up to 2,000 feet above sea level. For elevations above 2,000 feet, rated capacity should be reduced by 4% for each 1,000 feet above sea level. Based on 2500 BTU/Ft.3. The air flow must be adjusted to obtain a temperature rise within the range shown. Continuous return air temperatures should not be below 55°F. COMBUSTION DISCHARGE GAS CONNECTION GAS PIPING The gas supply line can be routed through the hole located on the left side of the unit. Refer to Figure 5 to locate these access openings. Typical supply piping arrangements are shown in Figure 3. Proper sizing of gas piping depends on the cubic feet per hour of gas flow required, specific gravity of the gas and the length of run. National Fuel Gas Code Z223.1 or CAN/CGA B149.1 or .2 should be followed in all cases unless superseded by local codes or gas company requirements. Refer to Tables 5 and 6. The heating value of the gas may differ with locality. The value should be checked with the local gas utility. NOTE: There may be a local gas utility requirement specifying a minimum diameter for gas piping. All units require a 1/2 inch pipe connection at the gas valve. Unitary Products Group Gas piping recommendations: 1. A drip leg and a ground joint union must be installed in the gas piping. 2. When required by local codes, a manual shut-off valve may have to be installed outside of the unit. 3. Use wrought iron or steel pipe for all gas lines. Pipe dope should be applied sparingly to male threads only. 9 66324-YIM-B-1004 . TABLE 6: PROPANE (LP) GAS PIPE SIZING CHART1 A U T O M A T IC G A S V A L V E 1 /2 x 1 /2 U N IO N LENGTH IN FEET 1 /2 x 1 /2 G A S C O C K NOMINAL INCHES IRON PIPE SIZE 1/2” 3/4” 1” 1-1/4” 10 275 567 1,071 2,205 20 189 393 732 1,496 30 152 315 590 1,212 40 129 267 504 1,039 50 114 237 448 913 60 103 217 409 834 70 96 196 378 771 80 89 185 346 724 90 83 173 322 677 100 78 162 307 630 1 /2 - 1 4 N P T D R IP L E G FIGURE 5 - EXTERNAL SUPPLY CONNECTION EXTERNAL SHUT-OFF TABLE 5: NATURAL GAS PIPE SIZING CHART1 LENGTH IN FEET 1/2” 3/4” 1” 1-1/4” 10 132 278 520 1,050 20 92 190 350 730 30 73 152 285 590 40 63 130 245 500 50 56 115 215 440 60 50 105 195 400 70 46 96 180 370 80 43 90 170 350 90 40 84 160 320 100 38 79 150 305 1. 10 NOMINAL INCHES IRON PIPE SIZE Maximum capacity of pipe in cubic feet of gas per hour (based upon a pressure drop of 0.3 inch water column and 0.6 specific gravity gas). 1. Maximum capacity of pipe in thousands of BTU per hour (based upon a pressure drop of 0.5 inch water column). If flexible stainless steel tubing is allowed by the authority having jurisdiction, wrought iron or steel pipe must be installed at the gas valve and extend a minimum of two (2) inches outside of the unit casing. i Natural gas may contain some propane. Propane being a excellent solvent, will quickly dissolve white lead or most standard commercial compounds. Therefore, a special pipe dope must be applied when wrought iron or steel pipe is used. Shellac base compounds such as gaskoloc or stalastic, and compounds such as rectorseal # 5, Clyde’s or John Crane may be used. Unitary Products Group 66324-YIM-B-1004 4. All piping should be cleaned of dirt and scale by hammering on the outside of the pipe and blowing out the loose dirt and scale. Before initial start-up, be sure that all of the gas lines external to the unit have been purged of air. 5. The gas supply should be a separate line and installed in accordance with all safety codes as prescribed under Limitations. After the gas connections have been completed, open the main shut-off valve admitting normal gas pressure to the mains. Check all joints for leaks with soap solution or other material suitable for the purpose. NEVER USE A FLAME. 6. The furnace and its individual manual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.48 kPa). The furnace must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.48 kPa). FLUE VENT HOOD The flue vent hood with screen is not shipped attached. This hood must be installed to assure proper unit operation. The hood must be fastened to the outside of the side gas control/ electrical compartment with the screws provided in the bag attached to the inside of the gas control/electrical compartment, see Figure 4. V E N T O U T L E T S C R E E N F L U E V E N T O U T L E T A IR H O O D FIGURE 6 - FLUE VENT OUTLET AIR HOOD The flue exhaust hood must be properly installed and within the recommended clearances. Further communications and action must be given to the home or building owner(s) to eliminate any unauthorized human contact around this area during the heating cycle. Flue hood surface and immediate area are designed to operate at high temperatures during the heating cycle. Flue hood surfaces may be hot. Unitary Products Group 11 66324-YIM-B-1004 TABLE 7: PHYSICAL DATA DNH MODEL EVAPORATOR BLOWER EVAPORATOR COIL CONDENSER FAN CONDENSER COIL CHARGE FILTER CENTRIFUGAL BLOWQER (Dia. x Wd. in.) FAN MOTOR HP (3 Speed) ROWS DEEP FINS PER INCH FACE AREA (Sq. Ft.) PROPELLER DIA. (in.) FAN MOTOR HP NOM. CFM TOTAL ROWS DEEP FINS PER INCH FACE AREA (Sq. Ft.) REFRIGERANT 22 (lbs./oz.) FACE AREA (Sq. Ft.) Size (Nominal) FURNACE SECTION NATURAL GAS BURNER ORIFICE NO. (Drill Size) PROPANE BURNER ORIFICE NO. (Drill Size) GAS CONNECTION SIZE COMPRESSOR HERMETIC TYPE, (Qty. = 1) 018 024 030 036 042 048 060 10 X 8 1/2 2 13 3.5 22 1/4 1,800 1 20 11.7 4/6 10 X 8 1/2 2 15 3.5 22 1/4 2,200 1 20 11.7 4/6 10 X 8 1/2 3 13 3.5 22 1/4 2,400 1 20 11.7 4/9 11 x 10 3/4 3 13 3.5 22 1/4 2,400 2 20 11.7 6 / 12 2.6/20x20 2.6/20x20 2.6/20x20 2.6/20x20 11 x 10 3/4 3 13 4.5 22 1/4 2,400 1 20 14.7 5 / 14 3.3/20x12 (2 Reqd.) 12 x 11 3/4 3 16 4.5 22 1/3 3,000 2 20 14.7 8/0 3.3/20x12 (2 Reqd.) 12 x 11 1 3 16 4.5 22 1/3 3,000 2 20 14.7 8 / 12 3.3/20x12 (2 Reqd.) 43 43 43 43 40 40 40 55 55 55 55 53 53 53 1/2 NPTI 1/2 NPTI Recip Recip 1/2NPTI Scroll 1/2 NPTI Scroll 1/2 NPTI Scroll 1/2 NPTI Scroll 1/2 NPTI Scroll TABLE 8: ELECTRICAL DATA MODEL DNH POWER SUPPLY 018 024 030 030 030 036 036 036 036 042 042 042 042 048 048 048 048 060 060 060 060 208/230-1-60 208/230-1-60 208/230-1-60 208/230-3-60 460-3-60 208/230-1-60 208/230-3-60 460-3-60 575-3-60 208/230-1-60 208/230-3-60 460-3-60 575-3-60 208/230-1-60 208/230-3-60 460-3-60 575-3-60 208/230-1-60 208/230-3-60 460-3-60 575-3-60 1. 2. 12 VOLTAGE LIMITATIONS1 MIN. MAX. RLA LRA COND. FAN MOTOR, FLA 187 187 187 187 414 187 187 414 518 187 187 414 518 187 187 414 518 187 187 414 518 253 253 253 253 504 253 253 504 630 253 253 504 630 253 253 504 630 253 253 504 630 7.1 9.3 13.6 8.6 4.3 17.2 11.4 5.7 4.7 20.0 13.9 6.4 5.4 23.4 13.0 6.4 5.1 32.1 19.3 10.0 7.9 48 57 67 55 27 88 77 39 31 104 88 44 34 126 93 46.5 37.2 175 123 62 50 1.1 1.1 1.1 1.1 0.6 1.1 1.1 0.6 0.4 1.3 1.3 0.7 0.5 1.9 1.9 1.0 0.8 1.9 1.9 1.0 0.8 COMPRESSOR SUPPLY AIR BLOWER MOTOR FLA 2.6 2.6 2.6 2.6 1.4 3.5 3.5 1.8 1.5 3.5 3.5 1.8 1.5 4.2 4.2 2.1 1.7 9.4 9.4 9.4 2.8 MINIMUM CIRCUIT AMPACITY 12.5 15.3 20.7 14.5 7.4 26.1 18.9 9.5 7.8 29.8 22.2 10.5 8.8 35.4 22.4 11.1 8.9 51.4 35.4 18.2 13.5 MAX. MAX. HACR FUSE SIZE, BREAKER SIZE, AMPS2 AMPS 15 15 20 20 30 30 20 20 15 15 35 35 30 30 15 15 15 15 40 40 30 30 15 15 15 15 45 45 30 30 15 15 15 15 70 70 45 45 25 25 20 20 UNIT POWER FACTOR TRANSFORMER SIZE (VA) .96 .96 .96 .96 .96 .96 .96 .96 .96 .96 .96 .96 .96 .96 .96 .96 .96 .96 .96 .96 .96 40 40 40 75 75 40 75 75 75 40 75 75 75 40 75 75 75 40 75 75 75 Rated in accordance with ARI Standard 110, utilization range “A”. Dual element, time delay type. Unitary Products Group 66324-YIM-B-1004 VENT AIR OUTLET HOOD BLOWER SERVICE ACCESS COMPARTMENT GAS SUPPLY 1-1/4" DIA. PANEL HOLE (1/2" NPTI CONNECTION) CONDENSER COIL UNIT CONDENSATE CONNECTION 3/4" NPTI (TRAP RECOMMENDED) A 2-3/8 HIGH VOLTAGE CONN. 1-3/8" DIA. KNOCKOUT HIGH VOLTAGE CONN. 7/8" DIA. KNOCKOUT B 3-3/4 REFRIGERANT CONNECTIONS COMBUSTION AIR INLET LOUVERS FRONT 2-1/2 GAS SUPPLY 1-1/4" DIA. KNOCKOUT (1/2" NPTI CONNECTION) LOW VOLTAGE CONN. 1-3/8" DIA. KNOCKOUT X 7/8" HOLE 47-1/4 (OVERALL) FIGURE 7 - 018 - 036 042 - 060 3-1/3 11 12-3/4 GAS/ELECTRIC CONTROL SERVICE ACCESS (OVERALL) COMPARTMENT PANEL 49-1/8 All dimensions are in inches. They are subject to change without notice. Certified dimensions will be provided upon request. 2-5/8 UNIT DIMENSIONS - FRONT TABLE 9: UNIT DIMENSIONS FRONT UNIT SIZE 5-3/8 1-1/2 DIMENSION “A” 33-1/2 41-1/2 “B” 18-1/4 23-1/8 TABLE 10: UNIT MINIMUM CLEARANCES1 2 CLEARANCES FRONT BACK LEFT SIDE (Filter-Access) RIGHT SIDE 1. 2. 3. 4. Unitary Products Group 36” 0” 24” 12” BELOW UNIT3 0” ABOVE UNIT 4 36” (For Condenser Air Discharge A 1” clearance must be provided between any combustible material and the supply 7 air ductwork. The products of combustion must not be allowed to accumulate within a confined space and recirculate. Units may be installed on combustible floors made from wood or class A, B, or C roof covering material. Units must be installed outdoors. Overhanging structures or shrubs should not obstruct condenser air discharge outlet. 13 66324-YIM-B-1004 H IG H V O L T A G E C O N N . 1 -3 /3 2 " D IA . K N O C K O U T 8 -7 /8 1 1 -7 /8 1 9 -1 /4 F R O N T G A S S U P P L Y 1 -5 /8 " D IA . K N O C K O U T (1 /2 " N P T I C O N N E C T IO N ) L O W V O L T A G E C O N N . 1 /8 " D IA . K N O C K O U T 4 -5 /8 C O N D E N S A T E D R A IN 3 /4 "' N P T I 2 6 -3 /4 6 FIGURE 8 - UNIT DIMENSIONS - FRONT & BOTTOM S ID E S U P P L Y A IR O P E N IN G 1 4 -1 /2 2 8 -3 /8 C O N D E N S E R C O IL 1 4 -1 /2 B A C K B O T T O M S U P P L Y A IR O P E N IN G 3 -3 /8 S ID E R E T U R N A IR O P E N IN G 1 4 -1 /2 4 1 -3 /4 3 -1 /2 1 5 1 5 1 -3 /4 1 5 2 9 -9 /1 6 FIGURE 9 - 14 B O T T O M R E T U R N A IR O P E N IN G 3 -1 /2 1 -3 /4 UNIT DIMENSIONS - BACK & BOTTOM Unitary Products Group 66324-YIM-B-1004 SEQUENCE OF OPERATION CIRCULATING FAN The unit is controlled by a conventional four wire heating/ cooling thermostat common to this class of equipment. When the thermostat calls for FAN, the thermostat terminal G is energized signaling the circulating fan to run at the heat speed 2 seconds after the G terminal is energized. HEATING When the thermostat calls for HEAT, the thermostat terminal W is energized, energizing the combustion air blower. After airflow is established, the air proving switch closes, the hot surface ignitor is energized and the pilot valve opens igniting the pilot flame. The flame rod senses a flame and de-energizes the ignitor opening the main gas valve and the main burners light. 30 seconds after the main burners light the circulating fan is energized at the heating speed. If a call for HEAT occurs, the circulating fan continues to run at the heat speed. If a call for COOL occurs, the circulating fan switches to cool speed after a 4 second delay. When the thermostat ends the call for FAN, the thermostat terminal G is de-energized, de-energizing the circulating fan. START-UP PRE-START CHECK LIST Complete the following checks before starting the unit. When the thermostat is satisfied, terminal W is de-energized, de-energizing the ignition system closing the gas valve. 1. Check the type of gas being supplied. Be sure that it is the same as listed on the unit nameplate. After a 5 second postpurge timing period, the combustion air blower is de-energized and the heat fan off timing begins. 2. Make sure that the vent outlet air hoods has been properly installed. When this field selected heat fan off timing is completed the circulating fan is de-energized. OPERATING INSTRUCTIONS If the primary, rollout and auxiliary limit switches open, the thermostat and ignition system is de-energized and the gas valve closes. The combustion blower and the circulating fan, at heat speed, are energized. The combustion blower remains energized for the 5 second postpurge timing period if the primary, rollout and auxiliary limit switches remake the contact (the rollout and auxiliary limit switches must be manually reset). The circulating fan remains energized for the selected heat delay off timing. 1. STOP! Read the information on the unit safety label. 2. Set the thermostat to the OFF position. 3. Turn off all electrical power to the unit. 4. DO NOT try to light the burners by hand. This appliance is equipped with an ignition device which automatically lights the burners. 5. Remove the access panel. 6. Turn the gas valve switch to the OFF position. 7. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow B in the information on the unit safety label. If you don't smell gas, go to the next step. 8. Turn the gas valve switch to the ON position. 9. Replace the control access panel. Normal operation of the system resumes. COOLING When the thermostat calls for COOL, the thermostat terminals G and Y are energized signaling the compressor and outdoor fan to run. After a cool fan on delay timing of 2 seconds, the circulating fan is energized at cooling speed. When the thermostat is satisfied, terminals G and Y are deenergized, de-energizing the compressor and outdoor fan. 10. Turn on all electric power to the unit. 11. Set the thermostat to the desired setting. 12. If the unit will not operate, follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier. TO TURN OFF GAS TO UNIT After a cool fan off delay timing of 30 seconds the circulating fan is de-energized. Unitary Products Group 1. Set the thermostat to the OFF position. 2. Turn off all electric power to the appliance if service is to be performed. 15 66324-YIM-B-1004 3. Remove the control access panel. 4. Turn the gas valve switch to the OFF position. DO NOT FORCE. 5. Replace the control access panel. L IN E P R E S S U R E T A P POST-START CHECK LIST (GAS) After the entire control circuit has been energized and the heating section is operating, make the following checks: 1. Check for gas leaks in the unit piping as well as the supply piping. 2. Check for correct manifold gas pressures. See Checking Gas Input. 3. Check the supply gas pressure. It must be within the limits shown on rating nameplate. Supply pressure should be checked with all gas appliances in the building at full fire. At no time should the standby gas line pressure exceed 10.5", nor the operating pressure drop below 4.5" for natural gas units. If gas pressure is outside these limits, contact the local gas utility for corrective action. M A N IF O L D P R E S S U R E A D J U S T M E N T (R E M O V E C A P ) 1 /2 - 1 4 N P T (IN L E T ) V E N T P R E S S U R E L IM IT E R FIGURE 11 - GAS VALVE - REAR Adjust as follows: 1. Remove the cap from the valve body. See Figure 6 for location. 2. To decrease the gas pressure, turn the adjusting screw counterclockwise. 3. To increase the gas pressure, turn the adjusting screw clockwise. MANIFOLD GAS PRESSURE ADJUSTMENT Small adjustments to the gas flow may be made by turning the pressure regulator adjusting screw on the automatic gas valve. Refer to Figure 6. MANUAL GAS SWITCH (SHOWN IN "OFF POSITION) NOTE: IGNITOR ELECTRICAL CONNECTION MANIFOLD PRESSURE TAP CONTROL ELECTRICAL CONNECTION GROUND TERMINAL 1/2-14 NPT (OUTLET) BURNER INSTRUCTIONS To check or change the burners, CLOSE THE MAIN MANUAL SHUT-OFF VALVE AND SHUT OFF ALL POWER TO THE UNIT. 1. Remove the two (2) #8 screws holding each burner in place. 2. Remove the burner assembly from the manifold assembly by moving the burner assembly forward, turn at an angle and pull back. 3. Burners are now accessible for service. PILOT GAS CONNECTION PILOT ADJUSTMENT The correct manifold pressure for natural gas furnaces is 3.5 IWG 0.2. The correct manifold pressure for propane (LP) is 10.0 IWG 0.2. FIGURE 10 - GAS VALVE - FRONT 16 Unitary Products Group 66324-YIM-B-1004 HOT SURFACE PILOT INSTRUCTIONS 2. To check, adjust or remove the hot surface pilot assembly, CLOSE THE MAIN MANUAL SHUT-OFF VALVE AND SHUT OFF ALL POWER TO THE UNIT. ADJUSTMENT OF TEMPERATURE RISE The pilot flame should envelope 1/2 inch of the end of the flame sensor and not contain any yellow color, see Figure 7. Lift the pilot and sensor from the assembly. Care must be taken not to damage the pilot or sensor when removing this assembly. BTUH Output Degrees F Temp Rise = -----------------------------------1.08 × CFM OR 3 /8 FIGURE 12 - PROPER FLAME ADJUSTMENT To adjust the pilot flame: BTUH Output CFM = ------------------------------------------------------------------------1.08 × Degrees F Temp Rise The temperature rise (or temperature difference between the return air and the heated air from the furnace) must lie within the range shown on the rating plate and the data in Tables 3 and 4. 1. Remove the pilot adjustment cover screw. 2. Adjust the pilot adjustment screw to achieve the proper pilot flame. After the temperature rise has been determined, the CFM can be calculated as follows: 3. Replace the pilot adjustment cover screw after the pilot flame is set. After about 20 minutes of operation, determine the furnace temperature rise. Take readings of both the return air and the heated air in the ducts about six feet from the furnace where they will not be affected by radiant heat. Increase the blower CFM to decrease the temperature rise; decrease the blower CFM to increase the rise. To remove the hot surface pilot assembly: 1. Disconnect the wiring from the gas valve to the hot surface pilot assembly. 2. Remove the two (2) #8 screws holding the hot surface pilot assembly in place. 3. Remove the hot surface pilot assembly. To remove the hot surface ignitor and flame sensor assembly: DIRECT DRIVE BLOWER All units have direct drive multi-speed blower motors. Refer to the unit wiring diagram and connect the blower motor for the desired CFM. CHECKING GAS INPUT 1. Remove the clip attaching the ignitor and sensor assembly as shown in Figure 8. FIGURE 13 - IGNITOR AND FLAME SENSOR ASSEMBLY Unitary Products Group NATURAL GAS 1. Turn off all other gas appliances connected to the gas meter. 2. With the furnace turned on, measure the time needed for one revolution of the hand on the smallest dial on the meter. A typical gas meter usually has a 1/2 or a 1 cubic foot test dial. 3. Using the number of seconds for each revolution and the size of the test dial increment, find the cubic feet of gas consumed per hour from Table 9. If the actual input is not within 5% of the furnace rating with allowance being made for the permissible range of the regulator setting, replace the orifice spuds with spuds of the proper size. 17 66324-YIM-B-1004 NOTE: To find the BTU input, multiply the number of cubic feet of gas consumed per hour by the BTU content of the gas in your particular locality. (Contact your gas company for this information since it varies widely from city to city.) TABLE 11: GASE RATE - CUBIC FEET PER HOUR1 SECURE OWNER'S APPROVAL When the system is functioning properly, secure the owner's approval. Show him the location of all disconnect switches and the thermostat. Teach him how to start and stop the unit and how to adjust temperature settings within the limitations of the system. Advise him that the flue exhaust hood surface and the immediate area will experience high temperatures during the heating cycle. All unauthorized personnel and debris must be kept away from this area. MAINTENANCE NORMAL MAINTENANCE Prior to any of the following maintenance procedures, shut off all power to the unit, to avoid personal injury. Periodic maintenance consists of changing or cleaning filters. Under some conditions, the main burners should be cleaned. FILTERS Inspect once a month. Replace Disposable or clean Permanent Type as necessary. DO NOT replace Permanent Type with Disposable. MOTORS Indoor and outdoor fan motors, along with the combustion blower are permanently lubricated and require no maintenance. 1. SECONDS FOR ONE REV. 1/2 CU. FT. 1 CU. FT. 10 180 360 12 150 300 14 129 257 16 113 225 18 100 200 20 90 180 22 82 164 24 75 150 26 69 138 28 64 129 30 60 120 32 56 113 34 53 106 36 50 100 38 47 95 40 45 90 42 43 86 44 41 82 46 39 78 48 37 75 50 36 72 52 35 69 54 34 67 56 32 64 58 31 62 60 30 60 SIZE OF TEST DIAL EXAMPLE: By actual measurement, it takes 38 seconds for the hand on the 1-cubic foot dial to make a revolution with just a 100,000 BTUH furnace running. Using this information, locate 38 seconds in the first column of Table 11. Read across to the column headed “1 Cubic Foot,” where you will see that 95 cubic feet of gas per hour are consumed by the furnace at that rate. Multiply 95 x 1050 (the BTU rating of the gas obtained from the local gas company). The result is 99,750 BTUH, which is close to the 100,000 BTUH rating of the furnace. OUTDOOR COIL Dirt should not be allowed to accumulate on the outdoor coil surface or other parts in the air circuit. Cleaning should be as often as necessary to keep the coil clean. Use a brush, vacuum cleaner attachment, or other suitable means. If water is used to clean the coil, be sure that the power to the unit is shut off prior to cleaning. 18 Exercise care when cleaning the coil so that the coil fins are not damaged. Do not permit the hot condenser air discharge to be obstructed by overhanging structures or shrubs. Unitary Products Group 66324-YIM-B-1004 BURNER 6. After brushing is complete, blow all brushed areas with air or nitrogen. Vacuum as needed. At the beginning of each heating season, make a visual check of the main burner flame. If it is not possible to adjust for the proper flame, the burners may need cleaning. 7. Replace parts in the order they were removed in steps 1 through 3. TO CLEAN BURNERS Remove them from the furnace as explained in Burner Instructions. Clean burners with hot water applied along top of the burner. COMBUSTION AIR DISCHARGE Visually inspect discharge outlet periodically to insure soot and dirt buildup is not excessive. If necessary, clean to maintain adequate combustion air discharge. The manufacture recommends that the furnace system be inspected once a year by a qualified service person. CHECKING SUPPLY AIR CFM To check the supply air CFM after the initial balancing has been completed: 1. Remove the two ¼ inch dot plugs in the duct panel. 2. Insert at least 8 inches of ¼ inch tubing into each of these holes for sufficient penetration into the airflow on both sides of the indoor coil. 3. Using an inclined manometer, determine the pressure drop across the dry evaporator coil. Since the moisture on an evaporator coil may vary greatly, measuring the pressure drop across a wet coil under field conditions would be inaccurate. To ensure a dry coil, the compressors should be deactivated while the test is being run. 4. Knowing the pressure drop across a dry coil, the actual CFM through the unit can be determined from the curve in Coil Delta P vs. Supply Air CFM figure. CLEANING FLUE PASSAGES AND HEATING ELEMENTS With proper combustion adjustment the heating element of a gas fired furnace will seldom need cleaning. If the element should become sooted, it can be cleaned as follows: 1. Remove the burner assembly as outlined in BURNER INSTRUCTIONS. 2. Remove the screws securing the restrictor plate to the tube sheet. 3. Using a wire brush on a flexible wand, brush out the inside of each heat exchanger from the burner inlet and flue outlet ends. 4. Brush out the inside of the restrictor plate to the tube sheet. 5. If soot build-up is particularly bad, remove the vent motor and clean the wheel and housing. Unitary Products Group Failure to properly adjust the total system air quantity can result in extensive system damage. After readings have been obtained, remove the tubes and reinstall the two ¼ inch plugs removed in Step 1. De-energize the compressors before taking any test measurements to ensure a dry indoor coil. 19 66324-YIM-B-1004 D1NH Coil Delta P vs Airflow 0.9 D1NH018 D1NH030-36 D1NH042-60 0.8 D1NH024 0.7 D1NH018 ID Coil Delta P 0.6 D1NH024 D1NH030-36 0.5 D1NH042 D1NH048-60 Linear (D1NH018) 0.4 Linear (D1NH024) Linear (D1NH030-36) 0.3 Linear (D1NH048-60) 0.2 0.1 0 400 600 800 1000 1200 1400 1600 1800 2000 2200 Airflow (CFM) FIGURE 14 - D1NH COIL DELTA P VS. AIRFLOW TABLE 12: SUPERHEAT CHARGING TABLE FOR D1NH018 OUTDOOR TEMP. °F 20 SUPERHEAT AT COMPRESSOR SUCTION (F), AIRFLOW = 600 CFM INDOOR WB TEMP. (°F) 55 57 59 61 63 65 67 69 71 73 75 65 30.7 31.2 31.8 32.3 32.9 33.4 34.0 34.2 34.4 34.7 34.9 70 22.9 24.4 25.8 27.3 28.8 30.2 31.7 32.1 32.6 33.0 33.4 75 15.1 17.5 19.9 22.2 24.6 27.0 29.4 30.0 30.7 31.4 32.0 80 7.3 10.6 13.9 17.2 20.5 23.8 27.1 27.9 28.8 29.7 30.6 85 - - 8.0 12.2 16.4 20.6 24.8 25.9 27.0 28.1 29.2 90 - - 5.5 8.6 11.7 14.8 17.9 20.4 22.9 25.4 27.9 95 - - - 5.0 7.0 9.0 11.0 14.9 18.8 22.7 26.6 100 - - - - 5.5 7.0 8.5 12.2 15.8 19.5 23.2 105 - - - - - 5.0 6.0 9.5 12.9 16.3 19.7 110 - - - - - - - 6.7 9.9 13.1 16.3 115 - - - - - - - - 7.0 9.9 12.9 Unitary Products Group 66324-YIM-B-1004 TABLE 13: SUPERHEAT CHARGING TABLE FOR D1NH024 SUPERHEAT AT COMPRESSOR SUCTION (F), AIRFLOW = 800 CFM OUTDOOR TEMP. °F INDOOR WB TEMP. (°F) 55 57 59 61 63 65 67 69 71 73 75 65 29.2 29.5 29.7 30.0 30.2 30.5 30.7 31.5 32.2 33.0 33.8 70 25.1 25.8 26.4 27.0 27.7 28.3 29.0 29.8 30.7 31.6 32.5 75 21.0 22.0 23.1 24.1 25.1 26.2 27.2 28.2 29.2 30.2 31.2 80 16.9 18.3 19.7 21.2 22.6 24.0 25.5 26.5 27.6 28.7 29.8 85 12.8 14.6 16.4 18.2 20.1 21.9 23.7 24.9 26.1 27.3 28.5 90 5.7 8.0 10.4 12.7 15.1 17.4 19.8 21.8 23.8 25.7 27.7 95 - - - 7.3 10.1 13.0 15.9 18.7 21.4 24.2 26.9 100 - - - 5.6 7.7 9.9 12.0 15.2 18.4 21.6 24.8 105 - - - - 5.4 6.8 8.2 11.8 15.4 19.1 22.7 110 - - - - - - - 8.4 12.4 16.5 20.6 115 - - - - - - - - 9.4 14.0 18.5 TABLE 14: SUPERHEAT CHARGING TABLE FOR D1NH030 SUPERHEAT AT COMPRESSOR SUCTION (F), AIRFLOW = 1,000 CFM OUTDOOR TEMP. °F INDOOR WB TEMP. (°F) 55 57 59 61 63 65 67 69 71 73 75 65 23.8 25.6 27.5 29.3 31.1 32.9 34.7 35.3 35.9 36.5 37.0 70 19.5 21.8 24.1 26.4 28.8 31.1 33.4 34.1 34.9 35.6 36.3 75 15.1 18.0 20.8 23.6 26.5 29.3 32.1 33.0 33.9 34.7 35.6 80 10.8 14.1 17.4 20.8 24.1 27.5 30.8 31.8 32.9 33.9 34.9 85 6.4 10.3 14.1 18.0 21.8 25.7 29.5 30.7 31.9 33.0 34.2 90 - 6.3 10.2 14.1 18.0 21.9 25.8 27.5 29.1 30.8 32.5 95 - - 6.3 10.2 14.2 18.1 22.1 24.2 26.4 28.5 30.7 100 - - 5.4 8.4 11.4 14.4 17.4 20.1 22.8 25.5 28.2 105 - - - 6.6 8.7 10.7 12.7 16.0 19.2 22.4 25.7 110 - - - - 5.9 7.0 8.0 11.8 15.6 19.4 23.2 115 - - - - - - - 7.7 12.0 16.4 20.7 TABLE 15: SUPERHEAT CHARGING TABLE FOR D1NH036 SUPERHEAT AT COMPRESSOR SUCTION (F), AIRFLOW = 1,200 CFM OUTDOOR TEMP. °F INDOOR WB TEMP. (°F) 55 57 59 61 63 65 67 69 71 73 75 65 32.4 33.0 33.5 34.0 34.6 35.1 35.6 35.7 35.8 35.9 36.0 70 29.1 29.8 30.5 31.2 31.9 32.6 33.3 33.6 33.9 34.2 34.4 75 25.7 26.6 27.5 28.4 29.3 30.1 31.0 31.5 31.9 32.4 32.8 80 22.4 23.5 24.5 25.6 26.6 27.7 28.7 29.3 30.0 30.6 31.2 85 19.1 20.3 21.5 22.7 24.0 25.2 26.4 27.2 28.0 28.8 29.6 90 13.5 15.2 16.8 18.5 20.2 21.9 23.6 24.8 26.0 27.2 28.4 95 7.9 10.0 12.2 14.3 16.4 18.6 20.7 22.3 24.0 25.6 27.2 100 6.4 8.0 9.6 11.3 12.9 14.5 16.2 18.4 20.7 23.0 25.2 105 - 6.0 7.1 8.2 9.3 10.5 11.6 14.5 17.4 20.3 23.3 110 - - - 5.2 5.8 6.4 7.1 10.6 14.2 17.7 21.3 115 - - - - - - - 6.7 10.9 15.1 19.3 Unitary Products Group 21 66324-YIM-B-1004 TABLE 16: SUPERHEAT CHARGING TABLE FOR D1NH042 OUTDOOR TEMP. °F SUPERHEAT AT COMPRESSOR SUCTION (F), AIRFLOW = 800 CFM INDOOR WB TEMP. (°F) 55 57 59 61 63 65 67 69 71 73 75 65 25.6 25.8 26.0 26.2 26.5 26.7 26.9 27.4 27.9 28.4 28.9 70 23.3 23.7 24.0 24.4 24.8 25.1 25.5 26.0 26.6 27.1 27.7 75 21.1 21.6 22.1 22.6 23.1 23.6 24.1 24.7 25.3 25.9 26.5 80 18.8 19.4 20.1 20.7 21.3 22.0 22.6 23.3 23.9 24.6 25.2 85 16.5 17.3 18.1 18.9 19.6 20.4 21.2 21.9 22.6 23.3 24.0 90 14.3 15.1 15.9 16.6 17.4 18.2 19.0 20.0 21.0 22.0 23.0 95 12.1 12.9 13.7 14.4 15.2 15.9 16.7 18.0 19.4 20.7 22.0 100 9.4 10.1 10.7 11.4 12.1 12.7 13.4 15.3 17.2 19.1 21.0 105 6.7 7.3 7.8 8.4 9.0 9.5 10.1 12.6 15.1 17.5 20.0 110 - - - 5.4 5.9 6.3 6.8 9.8 12.9 16.0 19.0 115 - - - - - - - 7.1 10.8 14.4 18.0 TABLE 17: SUPERHEAT CHARGING TABLE FOR D1NH048 OUTDOOR TEMP. °F SUPERHEAT AT COMPRESSOR SUCTION (F), AIRFLOW = 1,600 CFM INDOOR WB TEMP. (°F) 55 57 59 61 63 65 67 69 71 73 75 65 23.8 25.1 26.5 27.8 29.1 30.5 31.8 32.8 3.7 34.7 35.7 70 22.4 23.4 24.4 25.3 26.3 27.3 28.2 29.7 31.1 32.5 33.9 75 21.1 21.7 22.3 22.9 23.5 24.1 24.7 26.6 28.5 30.3 32.2 80 19.7 20.0 20.2 20.4 20.6 20.9 21.1 23.5 25.8 28.2 30.5 85 18.4 18.2 18.1 17.9 17.8 17.7 17.5 20.3 23.2 26.0 28.8 90 13.1 13.0 12.9 12.8 12.7 12.6 12.5 16.6 20.7 24.7 28.8 95 7.9 7.8 7.7 7.6 7.6 7.5 7.4 12.8 18.1 23.5 28.9 100 6.1 6.1 6.1 6.2 6.2 6.3 6.3 11.1 15.9 20.7 25.4 105 - - - - - 5.0 5.2 9.4 13.6 17.8 22.0 110 - - - - - - - 7.7 11.3 14.9 18.5 115 - - - - - - - 6.0 9.0 12.1 15.1 TABLE 18: SUPERHEAT CHARGING TABLE FOR D1NH060 OUTDOOR TEMP. °F 22 SUPERHEAT AT COMPRESSOR SUCTION (F), AIRFLOW = 600 CFM INDOOR WB TEMP. (°F) 55 57 59 61 63 65 67 69 71 73 75 65 27.7 29.3 30.9 32.5 34.0 35.6 37.2 37.3 37.3 37.4 37.5 70 21.1 23.2 25.2 27.2 29.3 31.3 33.3 34.2 35.1 35.9 36.8 75 14.5 17.0 19.5 22.0 24.5 27.0 29.5 31.1 32.8 34.4 36.0 80 7.9 10.9 13.8 16.8 19.8 22.7 25.7 28.1 30.5 32.9 35.3 85 - - 8.2 11.6 15.0 18.4 21.8 25.0 28.2 31.4 34.6 90 - - 6.0 8.6 11.2 13.8 16.3 20.5 24.6 28.8 32.9 95 - - - 5.6 7.4 9.1 10.9 16.0 21.1 26.2 31.3 100 - - - - 5.8 7.1 8.4 12.6 16.8 21.0 26.2 105 - - - - - 5.0 5.9 9.2 12.5 15.8 19.0 110 - - - - - - - 5.8 8.2 10.5 12.9 115 - - - - - - - - - 5.3 6.8 Unitary Products Group 66324-YIM-B-1004 FIGURE 15 - TROUBLESHOOTING TROUBLESHOOTING NOTE: Before troubleshooting, familiarize yourself with the START-UP and CHECKOUT procedures. Troubleshooting of components necessarily requires opening the electrical control box with the power connected to the unit. Use extreme care when working with the live circuits! Check the unit nameplate for the correct line voltage and set the volt meter to the correct range before making any connections with line terminals. Unitary Products Group If the variable speed motor found in DNH060 models operates erratically check the fan control board for the presence of a break-off tab. Remove tab if present. The wire number or color and terminal designations referred to may vary. Check the wiring label inside the control box access panel for the correct wiring. 23 66324-YIM-B-1004 FIGURE 16 - TYPICAL WIRING DIAGRAM D1NH 018, 024, 030, 036, 048 (208/230-1-60 POWER SUPPLY) 24 Unitary Products Group 66324-YIM-B-1004 FIGURE 17 - TYPICAL WIRING DIAGRAM D1NH 030, 036, 042, 048 (208/230-3-60 POWER SUPPLY) Unitary Products Group 25 66324-YIM-B-1004 FIGURE 18 - TYPICAL WIRING DIAGRAM D1NH 030, 036, 042, 048 (460-3-60 POWER SUPPLY) 26 Unitary Products Group 66324-YIM-B-1004 FIGURE 19 - TYPICAL WIRING DIAGRAM D1NH 036, 042, 048, 060 (575-3-60 POWER SUPPLY) Unitary Products Group 27 66324-YIM-B-1004 FIGURE 20 - TYPICAL WIRING DIAGRAM D1NH 060 (208-230-1-60 POWER SUPPLY) 28 Unitary Products Group 66324-YIM-B-1004 FIGURE 21 - TYPICAL WIRING DIAGRAM D1NH 060 (208-230-3-60 POWER SUPPLY) Unitary Products Group 29 66324-YIM-B-1004 FIGURE 22 - TYPICAL WIRING DIAGRAM D1NH 060 (460-3-60 POWER SUPPLY) 30 Unitary Products Group 66324-YIM-B-1004 FIGURE 23 - WIRING DIAGRAM DETAIL B (460 & 575-3-60 POWER SUPPLY)1 1. See Figures 18 and 19. TYPICAL WIRING DIAGRAM NOTES (SEE FIGURES 16, 17, 18 AND 19) 1. All field wiring to be accomplished following city, local and/or national codes in effect at time of installation of this unit. Open all disconnects before servicing this unit. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation if any of the wire as supplied with this unit must be removed it must be replaced with type 105°C, 600V wire or equivalent clearly renumbered for identification. Verify proper operation after servicing. 2. Motors are inherently protected. 3. See unit nameplate for maximum fuse size and minimum circuit ampacity. 4. Unit factory wired for low or medium speed indoor blower operation to change motor speed connect speed tap wires from indoor blower motor per Detail B (Figure 23) tape unused speed tap wires to prevent shorting and secure near M2 contactor. 5. Select indoor blower speed to remain within the temperature rise range on the nameplate in heating and to obtain approximately 400 CFM/Ton in cooling. 6. If both LR and ASCT are present, wire 801/BL and 805/ BL are connected to ASCT-3 if LR only is present wire 801/BL and 805/BL are connected to M1 coil. If ASCT only is present wire 202/Y is connected to ASCT-3. If neither LR or ASCT are present, Wire 202/Y is connect to M1 coil. Unitary Products Group ! " " # $ #% # & $ # # '( ' ( # ") ( '* & ' ( '( ++ ⊗ '( ,,,,,,,,,,,, ( ( #&# & '( & & '( ' ( ( & & '( ' ( ( '&' & ( FIGURE 24 - TYPICAL WIRING DIAGRAM LEGEND1 1. See Figures 16, 17, 18 and 19 31 Subject to change without notice. Printed in U.S.A. Copyright © 2004 by Unitary Products Group. All rights reserved. Unitary Product Group 66324-YIM-B-1004 Supersedes: 66324-YIM-A-1003/035-18266-002-A-1003 5005 York Drive Norman OK 73069